Sound monitor for subsurface packer



l 1959 R. c. RUMBLE Erm. 2,915,739

SOUND MONITOR FOR SUBSURFACE PCKER Filed Dec. 7, 1956 2 Sheets-Sheet 1 Dec. l, 1959 R. c. RUMBLE ETAL 2,915,739

souND MONITOR FOR suBsURFAcE PACKER Filed Dec. 7, 1956 2 Sheets-Sheet 2 (200 |572 H uomToR AND molcATon j n EQUIPMENT s vous |J.cA

swlIcH PowEn |70 SUPPLY l 22 Vn Moron sEcTwN 4'/ Il /T l CABLE SHEATH l PR01-Ecrans REslsroR |45 J23 1 I v PUMP sEcrloN ATTO RN E Y.

United States Patent Research Company, Tulsa, Okla., a corporation of Delaware Application December 7, 1956, Serial No. 626,870V

3 Claims. (Cl. 340-18) This invention isdirected-to a; sound signalingy system. More particularly, thisinvention is directed to a sound signaling system for indicating an amount of internal pressure on an inflatable subsurface packer.

In our copending U.S. patent application Serial No. v

a. specified pumping time interval may be obtained. A v

further object of this invention is toprovide a system whereby indication ma-y be obtained of the packet pres,- sure after pumpinghas ceased; or indication that the packer has drained; or that the packer is leaking and the -degree. thereof; or that the motor is functioning properly including normal repetitive motor loading in Synchronizationwith pump reciprocation.

Briey, this invention comprises a signaling system for use in a subsurface fluid inflatable-deatable packer device provided with rotatable drive means, the inating and deating of the packer being dependent upon the direction of rotation of the drive means comprising an velectrical circuit connect-ing a power supply, atransformer, surface indicating means, and first and second switches,

2,9 15,739 Patented De@ it 1,955?

2 electrical; circuit to be described later her-'eine' 'I'helower end of cylinder 15 isV connected to a wall memben 23 by Vtrie/ans of threads 24 and a pressure s eal is. maintained at this, connection by means of; 0,.-ring. 25., Positionedr in section 11 as shown is a rayer/sible motor, such as a permanent magneti motor 2,9'. A transformen u nit 201 is positioned adjacent motor 2,49.

A housing 30 is attached to and shouldered against wall member 23 by means of, threads. Motorfza is P for' Videdj with a gear reduction; unit 2&2 and is mounted in housing 30 and connected theretoA hyl means oi set screws 3,1. The lower endY of housingr 31) holdS. theouter race of a thrust bearing 325.A A shoulder 3 4 formedon wall'mem: ber 23 provides a stop for housing 30. A n Output shaft of gear reduction unit 202 has mounted thereon for rotation therewith an; eccentric cam couplingy A pin 3 6 connects cant 37 to shaftl 35 A switch 203 is posi,- tioned' adjacent housing 30 andY includes, a switch contact 204 secured to gear reduction housing 202: b y means such as screws 2,05 and. a plunger 201 extending through lhousing 30, and biased by means of spring 208; into engagement with the surface ofcam coupling 37. Elunger 20.7 is electrically connected tov the secondary of trans,- forrner i201 by a conductor 222. Also, an electrical con,- ductor 223 connects the primary of transformer. 201 t0 motor 2,9.y An opening inthe lower end of cam coupling 37 is hexagonal in cross section in order to engage. with the upper end of a shaft 3 8 which is Vmilled tol ahexagonal cross section as shown on its upper end. Shaft 3 8 `extends through thev inner'race ofy thrust bearing 33 and is4 prevented from moving upwardly by a ang 39 formed' on shaft 3 8. The lower en di of shaft 38 below Hnge 391 has a` reduced diameter and is provided with. a milled polygonal crossse'cti'on for driving a helicalcarn the secondary of said transformer being shorted upon v closing of said switches, means responsive to uid pressure inl said packer for closing said lirst switch and means adapted to intermittently close said second switchin response to vrotation of said drive means.

Referring to the drawings:

Figs.` 1 through 3 are sectional views from top to bottomy respectively of the device of the present invennon;

Fig.v 4 is a schematic diagram including the electrical circuit employed in the operation of the device ofthe present invention; I

Fig. 5 is -an kelevational schematic view illustrating th device positionedy in a borehole. l 1

For a clear understanding ofthe elements and operation of this device, reference to Vthegures in. greater detail will now hemade. f

As seen in Figs. -1 through 3, `the device consists kessentially of four sections. These are a pressure sealed motor section 11, a pump section 12, a packer ,section 13 and aowmeter section '14. Section 11 (Fig. 1) consists of @hollow cylinder 15 which has connected to its upper end The pumpsection 12 consists of av cylinder 41 which is connected to Wall member 23 by means of threads 42 and to a lowerwall member 43 by means` of threads 44; A -iiuid seal surrounding the lower end portion of shaft 38 consistingl of a bronze bushing 5 0, an .Gering 51, and felt washers 52j, is housed'ina -rernoyahle holder 45whi'ch`, in turn,` is pressure sealedto-wall member 23 byv means of ano-ring 4 6. ,Grease escape ports 50a'are' provided in bronze bushing '50 to allow lO-ring 51 to form and cause a positive fluid sealbetween rotating shaft 38 and holder 45.. when iiuid pressure is exerted below packing 5 2 and G-ring 51. Holder 45, and the sealing elements c e- 52 are maintained in position by a shaft aligning a iishing; neck 1,6. This connection is pressure 'sealed by washer 45S which'is heldby screws 49threaded into wall member 2 3. A cylinder v53 i's shown (Fig. 2) screw threadedly attached to wall member ,43 as' atv 44a and attached at its upper end to acarn shaft holder 54 by vmeans of screws 54a. Cylinder 53 `has formed intermediate the length thereof longitudinal slits 55 and 55a and formed adjacent its Vlower end -uid draining Iports '56. Cylinder 41 is provided .with'fluid entry and draining slits 57 positioned adjacent ports v56. v ACam shaft holder 54v contains a sleeve bearinggSS and is yformedto provide aplongitudinallyextending port A lshaft 60, attached at its -upper end to helical cam 40 by means of pin 61, may rotatewfreely lin bearing 58; A Washer 62 Serves as a hearing between ,minable cam 41.0 and-camshaft hQldsfd- The upper end of'sam 4.0",i'sv a hollow cylinder kwhich contains an ,engaging member.. 63. Whih latter member iS ,-fQfmed -wifh a 1191.@-

upper end of shaft 60.'- The lower end ofl is i A u connected to a pawl holder 67 by means ofa pin 68.-

Pawl holder-67 carries two identical but oppositely directed `pawls 69` and70 mounted on a common pin 7L Pawl biasing spring 72is' mounted on V`a `pin 73. The lower end of pawl holder 67 spears into a bearing recess in a pawl follower 74, the bearing irecess being provided with a relief slot 77. Pawl follower 74 is `provided with a key 75 which projects internally from the pawl follower wall. A plurality of drain holes 76 permits drainage of any tluid or sediment that may enter pawl `follower 74. The pawl follower 74 is threadedly engaged to and movable in a wall member 78 by means of threads 79. Wall member 78 is aixed to cylinder 53 by means of screws 80. The lower end of pawl follower 74 is free to rotate in a cylinder head 81 but is constrained from longitudinal movement by means of a washer 82 positioned on the lower end of pawl follower 74. a

The cylinder head 81 forms the upper end of a` pump cylinder 83 and is connected thereto by means of a screw 84 which is free to lmove longitudinally in a slot 85 formed incylinder 53. The lower end of pump cylinder 83 is mounted on shoulder 88 of stinger '86 and is threadedly connected to stinger 86 by means of threads 87. Stinger 86 is provided with a fluid exhaust port 89 and an O-ring 91. The upper end of stinger `86 supports a spring 92 which in turn bears against a check member 93 positioned in a port 94 formed in the lower portion of cylinder 83. This permits only downward ow through port 94 in pump cylinder 83. A piston 95 is slidably `arranged in pump cylinder 83. The piston 95 is provided with a fluid entry portl 96, check 97, biasing spring 98, cup washer 99 and a retainer 100 which latter is threadedly connected to piston 95. Piston 95 is connected to a piston rod 102 by means of a pin 103. The piston rod 102 extends through a slit 104 formed in pump cylinder 83. Slit 104 in cylinder 83 and slit 55a in cylinder 53 are in alignment. t

The upper end of piston rod 102 is attachedto a ca follower wheel` 105 `by means of an axle 106. Cam follower wheel 105 moves in a continuous helical slot 107 in cam 40. Piston rod 102 extends through an opening in cam shaft holder 54 and moves longitudinally in akeyway 108 formed in a cylinder 109 which latter is attached at its lower end to cam shaft holder 54.

The packer section 13 consists of a tubular mandrel 115 which is preferably silver soldered to a packer stinger 116 which is pressure sealed from a packer adapter 110 by means of -ring 117. Stinger 116 shoulders against a ledge 119 formed in packer adapter 110 and the upper end thereof extends into a passageway 120 in wall member 43 where a uid seal is maintained by means of an O-rng 121. Stinger 116 is provided with a longitudinally extending'passageway V123 communicating with transverse ports 124 formed in tubular mandrel 115 which is thick-walled at its upper end and threadedly connected into the lower end of adapter 110. A plurality of longitudinally extending passageways 126 are provided throughout the length of the thick-walled portion of mandrel 115 and these passageways uidly communicate with ports 124 as seen in Fig. V3. A series of fluid inlet and outlet ports 127 extend` through the upper end of mandrel 115 between the passagewaysj126. A plug'128 screws into the bottom of stinger 116 in line with passageway 123. t e,

Wall member 43 is providedwith a chamber 210 (Fig. 2) `luidly communicating with passageway 120 by means of a port 211.` `The chamber 210 contains suitable filter material or screen 212. A` screw cap 213`is `ernployed to retain the lter material 212 in chamber 210`. A housing 214 (Fig. `l) is Vsecured to cylinder 41 bymeans of screws 215.` Housing 214 is formedrto provide a chamber 216 in which is positioned a diaphragm 217.

A switch 217a is positioned adjacent diaphragm 217 and includes a movable contact 218 and a stationary contact 219 both attached to housing 214. A conduit 220 fluidly communicates chamber 210 and one side of diaphragm 217. Contact 218 is spring biased against the other side of diaphragm 2,17 as shown. Thus, sufficient uid pressure in chamber 216 will force diaphragm 217 against the basvof contact 218 and thereby urge the contacts 218 and 219 into engagement. An electrical conductor 221 connects contact 204 of switch 203 to contact 219 of switch 217a.

A packer l129 is mounted on mandrel 1'15 with its upper end clamped by clamping ring 130 and threaded nut 131 while its lower end is clamped by clamping ring 132 and threaded nut 133. The latter is threadedly mounted on sleeve 134 which is, in turn, slidable on mandrel 115. A fluid seal is maintained between sleeve 134 and mandrel 115 by O-ring 136. Sleeve 134 may be locked on mandrel in any desired position byset screws '135. Asshown in Fig.- 3, passageways 126 uidly communicate with the interior of packer 129. Packer mandrel 1-1'5 is threadedly connected to the iiuid metering section |14 as at 137.

`The packer -may consist of a preformed oil resistantv Itial parts ofthe owmeter are asfollows:` a nose plug is connected to a cylindrical member 141 which, in turn, is screw threadedly connected to mandrel 115 at 137. The cylindrical member 141 is provided with fluid inlet and outlet ports 141a. A rotor `144 is mounted on a shaft 144:1 and stator deilectors 142 and 143 `are mounted below and above the rotor 144, respectively. A cam 145 is formed on shaft 144A an'd a spinner circuit breaker 146 which also acts as a cam follower is positioned so as to bear against `the cam 145 and is arranged to move in response to rotation of the cam `145 and to make and break contact with switch contact 146a in response to this movement. Cam 145 is designed to cause cam follower or circuit breaker 146 `to make and break contact with switch contact 146a in one sequence when the cam rotates in one direction `and in a different sequence `when the cam is rotatedin an opposite direction. Thus, codedt signals are generated which are transmitted tothe earths surface `as described hereinafter. The difference in the signals indicatesdirection of flow through -the meter and the rate at which the signals are transmitted indicates rate of fluid ow through the meter.

An' electrical conductor v147 connects to switch contact 146a and extends throughout the length of the device and into the motor section 11 where connection is made `with conductor 22 as shown more clearly in the electrical circuit diagram of Fig. 4. Although conductor's" 147 and 221 are each shown as individual continuous leads, it is obvious that anurnber` of slip ring connections would be included in order 'to `threadedly assemble the various sections. Also to facilitate assembly of the device, slit 55a should be a continuation of slit 55. Fig. 4 shows schematically the electric circuit involved in the operation of this device. On the surface is positioneda double-pole threefposition switch generally designated 170, a D.C. power `supply`171, a condenser 200 and monitor and indicator equipment 172. The switch has three positions designated l, 2 and 3 `which alternatively connect the monitor and indicator equipment 172 andthe D.C. power supply 171 in reverse polarities with Conductor cable 22. Sheath 21 is grounded as at 173. Conductor 22 connectsto ai relayJ 174 having contactsv 1177 and 178. Conductor 147 connects' in seriesicontact 177, resistor 1545 andiilow indicator switch elements146a and 146 grounded as at 176. The secondary" ofl transformer'201A is grounded as at 224:; housing 21f4-isgroundedasy at 225; and relayA 174 isf grounded as at 226.

vIn switch position 2, the conductor 22 is connected directlyto the monitor and' indicator equipment 172. Inv

the subsurface circuit relay 174 is not energized at this' time sincel thevol-tage impressed onconductor-22 by the monitor angd indicator equipment A 172 isvv ofy a relatively small amount," for" example, 'three volts; Hence; the spinner breaker 146- is' connected throughv relay contact :177, resistor 145 and lead'147`, to conductor 22.` In' this' positionythe owmeter functions as the spinnerdescribed in the Buck application noted supra. WithJ the switch 170 in position 1 or 3, the D.C. power supply is connected 'tof cable 122; Thisvoltage being higher, for example 65 volts,1 actuates the relay 174 so that the applied voltage is connected to the pump motor 29 through contact 178'V of relay 17-4. Pump motor29` rotates shaft 30` clockwise or counterclockwise depending on whether surface-switch 170 isinposition 1\ orl 3. Capacitor 200 couples one lead of conductor 22 to the indicator equipment 172 thus connecting in the indicator when the switch is in position 1 or 3.

The primary of transformer 201 is positioned in the motor current conductor 223 leading from contact 178 of relay 174 to motor 29. One terminal of the secondary of transformer 201 is grounded as at 224. The other terminal leads through switch 203, which is closed by rotation of eccentric cam 37 moving plunger 207 to engage contact 204 to switch 217a which is closed by movement of diaphragm 217 in response to fluid pressure in chamber 216 moving contact 218 to engage con-tact 219.

In general operation, the device is lowered in the well with the packer 129 in a deflated condition and with the switch 170 in position 2, as shown in Fig. 13. At a depth at which it is desired to take a reading, vertical travel of the device is arrested. Then switch 170 is thrown to position l which actuates pump motor 29 which causes rotation of shaft 38 in one circumferential direction which, in turn, rotates shaft 60 and cam 40. Rotation of cam 40 reciprocates piston rod 102 which forces fluid into the pump chamber 53a via ports 55a and 104 and check 97 and out pump chamber 53a through check 93. Also, pawl follower 74 moves downwardly on screw thread 79 in wall member 78 until pawl 69 moves over the top of key 75. This moves pump cylinder 83 downwardly carrying stinger 86 downwardly into passageway 120. O-ring 91 when positioned in passageway 120 prevents tluid from passing out ports 89 and directs uid coming from pump chamber 53a through passageways 120, 123, 124 and 126 into packer 129 to inflate the packer.

When a seal is effected by the packer 129 in the wellbore, the switch 170 is thrown back to position 2 so that a reading of the ow rate may be made on the monitor and indicator equipment 172. After the reading has been made and it is desired to retrieve the device or obtain another reading at a different depth, the packer is deflated preparatory to moving the device by positioning the switch at position 3 for a short time, for example 1/2 minute, then it is returned to position 2. This permits the packer to drain and leaves it in a condition to continue draining while raising and lowering the device. It is equally important that the packer be open to permit draining while being raised in the borehole since the decreased pressure at lesser depths in the well causes the gas in the vestige of oil remaining in the packer after deation to break out of solution. If the packer is not in draining condition when the device is raised, this liberated gas would cause expansion of the packer and thus agotarse 6 A cause damage to the packer. orprevent itsremoval from the-well. When the packer is sealed against' the: wellb'ore; any fluidl flow in the well will be diverted through the meteringA section 121iv via ports Mia-'and 127'. When a reading or measurement ofthe 'ow reading is made, the D-.C. power` supply 171" is disconnected from the upperterminus of the' cableV 22 thereby disconnecting the pump-motor 29" from thev power supply: When the pump motor ceases` to run, the packer remain'si'nflated, The relay 174 when not' energized will Vautomatically connect the spinner breaker 114.6 in the circuitI for measurement of the flow-'direction and rate; Y

Whenthe direction of rotation ofthe; armature of motor 20 is reversed byL reversing the polarity of the D.C. lsupply voltage 171'by moving the switch fromposition l to position 3; the directionof'rotation off pawl holder 67 is also reversed. Thisy causes pawl 70` to engage-'key- 7-5-of" pawll follower- '74 which, infturn, causes pawlifoll'ower-'74 to move upwardly withrespect to wall member 78fby means of the threadedy connection 79v in wall member 78. This'results4 in pump cylinder S3 being movedupwardly until the p ortsr 89 in stinger S6are withdrawn from passageway i By'uncovering portsy 39 thel flow'/ through" the stinger from pumpchamber' 5321 will pass outwardly through ports 89, 56 and 57. The ports 89 are uncovered after the motor 29 has run for approximately 5 seconds in the clockwise direction after which pawl 70 has slipped over the lower end of key 75. Hence, protracted running of the motor 29 in a reverse direction is not necessary to drain the packer.

The operation of the signaling system is as follows: When the pump motor 29 is energized by moving switch to position 1 and the pressure in the packer 129 is equal to or greater than a selected pressure, contact arm 218 grounds conductor 221 which shorts the secondary of the transformer 201 when switch 203 is closed by the rotating eccentric cam 37. The direct current flow to the motor 29 is modulated by motor noise. This noise is loud and readily distinguishable in the surface monitoring equipment which is capacitatively coupled to the line by capacitor 200 when the switch 170 is in either position 1 or 3.

When the secondary of transformer 201 is open (that is, when switches 203 and 217a are open) the inductive reactance of the primary is high which blocks much of the high frequencies of the motor noise.y When the secondary of the transformer is shorted the inductive reactance drops sharply, hence the high frequencies in the motor noise pass with little attenuation.

When the motor is running but the packer pressure is insuficient to cause contact arm 218 to ground conductor 221 a rather uniform note is emitted by the surface monitor loud speaker. As the packer pressure moves contact arm 218 to ground conductor 221 a high audio frequency chirp is emitted in synchronization with the closing of switch 203. Shorting of the transformer secondary lowers the inductive reactance of the primary, hence the high notes are not attenuated. i

Preferably the secondary of the transformer, having but few turns of large wire, is a low impedance low voltage circuit and thereby not subject to effective shorting by salt water which may ground conductor 221 to the surrounding metal. This type of circuit provides a distinguishable note when the packer is inflated. Other types of circuits may prove impracticable because of grounding of the conductor by saturated salt water.

The sound monitor system described herein will provide indication, among other things, that the packer has pumped to a certain pressure in a specified time interval of pumping.

Also, it can be ascertained what pressure is on the packer after an interval of time after pumping operations have ceased. It also may provide an indication that the packer has drained, and whether or not the packer has developed either a fast or slow leak. The motor noise itself gives aural indicationsr of proper functioning ofthe f motor and of `normal repetitive motor loading `in synf chronization with pump reciprocation.y f f Although they insulation risv not yspecifically designated yon thedrawing, yin eachinstance it is to be understood thatinsulation will beV provided elements requiring'sucb in order to form'the'circuit shown in Fig.,4. f f f Having describedtheapparatus, operation and objec ofy our invention, we claim: f f f f f 1.y A signaling system yforfusefvvith a rsubsurface..iiuidy f f rinflatable-deiiatable packer device provided with 'an elecf f ytric motorfhavingfa rotatable drive, (the inating and deating of said packer vbeingr dependent yupon y'the direc- ,r tion of rotation of said drive comprising an electricalr f circuit yincluding a D.C. power rsupplyvor `energizing said; system, indicating ymeans adaptedr to register relectrical signals transmittedthereto,y a transformer, a first'y f f y ,switchy and asecond switch; saidtmotor being connectedy tor one terminal of the primary ofy ,said transformer; f f f coupling `means connecting the other terminal of said y rprimary and ysaid indicating means; one terminal of the secondary; ofy said: transformer ybeing groundedy andthe other terminal of said secondary being connected to 'one' terminal of said rst switch; the other terminal of said tently said' rst drivel f 2. A system as recited in claim 1 wherein said pressure responsive means includes f a pressure 'chamber uidlyfcommu'nicating with thefinterior of said packery and a diaphragm arranged in said chamber 'movably yre-r sponsive 'to pressure changes within said packer. f

3i A system as recited ini claim 2 ywherein said drive rotation responsive means includes a cam mounted on f said dri'vefadapted to close intermittently said first switch uponrotation'ofsadidrive.'Lr i :y

i l References Citedfin the ile of this patent K 

